Metal Cutting

Material removal through cutting, turning, milling, drilling, grinding, tapping and more using machinery such as laser cutting systems, plasma cutting systems, oxyfuel cutting systems, milling machines, drill presses, lathes, horizontal machining centers, vertical machining centers, turning centers, multitasking machines, electrical discharge machines and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Numerical Control (CNC), automation and robotics.

High Speed Horizontal Machining of Largest Parts in Class

The HMC500 from OKK is built for speed and faster cycle times, with exceptionally fast automatic pallet and tool changers and the ability to complete deep boring operations without rotating the pallet.
Experts
Automation/Robotics

Intelligent Factories: The Fourth Industrial Revolution

The biggest challenge for intelligent metalworking shops is implementing the correct individualized manufacturing systems on the software side that can fit their unique needs and provide competitive advantages.
A new era of highly efficient, flexible and customizable mass production requires software and analytical systems that turn the deluge of data produced by intelligent factories into useful and valuable information.
CAD/CAM Software

Mission Accomplished

Robotic metal polishing; Mico Industries.
Thanks to SolidCAM iMachining, cycle times are down 50 percent, tool life is up 40 percent, and Mico Industries is creating dies, weld fixtures and check fixtures without compromise.
Drilling Machines

Making Natural Gas Clean with a “Hole” Lot of Pressure

A pressure vessel in the mid-fabrication stages. The pressure vessels Mueller Environmental manufacturers measure anywhere from 4 ft to 8 ft in diameter and are made from ½ in to 3 1/2 in thick 5617 rolled steel plate. The diameter and material thickness depends upon the pressure the vessel must withstand. Sometimes pressures can reach as high as 3,000 psi.
Using a modified HMD915 magnetic drill and Industrial Series of Rotabroach Cutters from Hougen enabled Mueller Environmental to cost-effectively develop a patented new system for cleaning natural gas.
Gear Cutting Machines

Gear Production: Higher Speed, Closer Precision

The accuracy of the Fast Gear Alignment function eliminates the need to acquire acoustic signatures during dressing or grinding. Aligning a grinding wheel with a 180 mm diameter gear with 71 helical teeth takes just 0.5 of a second – without any need to acquire acoustic signatures or make manual adjustments. 
Automated threaded wheel grinding on gear production machines has now been boosted by an order of magnitude with increased machining accuracy to DIN class 3.
Grinding Machines

Gear Hobbers and Control Migration

The machine utilizes full four-axis electronic gearbox capability of NUMgear to help speed production of complex gear parts. In conjunction with built-in high-speed synchronization facilities this allows the axial and radial feeds, and the hob head shift axis, to be geared to the work piece spindle.
This is the story of how Bourn & Koch upgraded its older gear hobbers to advanced CNC systems to machine large bull and cluster gears, worms, shafts, splines and pinions for the defense and aerospace, oil/gas drilling, mining, heavy equipment and power generation industries.
Honing Machines

A Chip Off the Old Block

Dart produces about 16,000 cylinder heads per year.
Dart masters the "peaks and valleys" of custom engine block production with an advanced American-made Sunnen SV-20 flexible honing system that uses programmable control to replicate “best” engine parameters and produce expert results with minimal operator expertise.
Horizontal Machining Centers

Advanced Machining Allows Subsea Valves To Handle the Pressure

Operating a DMG / Mori Seiki NL2500 at BEL Valves.
BEL Valves uses a variety of DMG / MORI SEIKI machine tools to meet its paramount need for reliability during production. 
Laser Cutting

Micromachining: No More Constraints

Prototyping time for new nozzle designs is reduced from weeks in the machine shop to 24 hours with the R-Drill, dramatically accelerating design optimization and time to market. The R-Drill reduces drilling time by approximately 30 percent while increasing yield to nearly 100 percent, with no need for expensive post-processing to correct HAZ damage.
The latest femtosecond laser technology from Raydiance can reduce cost per part by 20 percent to 50 percent and reduce product design, prototyping and development from months to as little as 24 hours.
Lathes

Hard Thread Turning Shortens The Process Chain

Figure 1. High rigidity allows higher process forces: Hembrug turning machines are especially suitable for high-precision hard turning.
High precision hard turning techniques are enjoying ever greater popularity in the metal processing industry. By shortening cycle times and increasing flexibility, high precision hard turning has advantages over grinding in particular when it comes to processing complicated parts such as spindle nuts or threaded spindles in the hard state.
Machine Controls

Custom CNC Helps Break New Ground

Innovative flying optics can position the XO machine’s laser beam anywhere within a 1.5 x 3 metre working area, to an accuracy of ±0.01 mm.
NUM develops special hardware and software for the XO laser cutter of Favor Laser, marking the company's entry into the high performance end of the market.
Milling Machines

Boring Mill Fuels Energy Sector Expansion for Machine Shop

The dual-pallet, rotary table Giddings & Lewis MC 1600 horizontal boring mill (HBM) from Fives is designed for multi-axis contour milling, precision boring, drilling and tapping. It will produce a variety of large parts for Milwaukee Machine Works, including wind turbine gearbox housings and fluid end manifolds for the oil/gas industry.
Milwaukee Machine Works expands its energy sector business into wind turbine gearbox housings, fluid end manifolds for the oil/gas industry, and other oversized components up to 10 ft long and weighing up to 7,000 lb with a new large capacity dual-pallet Giddings & Lewis MC 1600 from Fives.
Multitasking Machines

Shoot from the Hip

Custom shoulder implant parts on the NTX 2000 turn-mill center, which has opened up new possibilities for parts that previously required at least two operations. Rasp handles that were previously contracted outside will become some of the first components loaded on the new machine.
This orthopedics manufacturer achieves one hit machining in an automated lights-out environment using advanced turn-mill machines that take their custom implants for coated hip replacement to a whole new efficiency.
Ram EDM Machines

A Hole New Game: Precision EDM Holemaking Goes Smaller, Deeper and Faster

Technically advanced EDM drill systems merge hole popper technology with die-sinker digital generator technology for more precise spark control that essentially puts the holemaking accuracy in the technological hands of the machine tool.
While hole-popper systems are quite capable of generating very small accurate holes with good surface quality, advanced EDM drilling systems dramatically increase a shop’s capability to consistently produce tiny holes that are even more accurate and with higher quality.
Software

How to Simplify Complex Geometry Tool Repair

By enabling the entry point of the grinding wheel to follow the corner radius of the cutting edge, the software now facilitates the grinding of a defined rake angle on complex body forms and on cutting edges which pass from the body of the tool to its tip – a task that was previously extremely difficult to achieve.
A new release of NUMROTO tool grinding software meets the growing challenges of grinding and servicing new generations of complex geometry drills and end mills.
Vertical Machining Centers

All-Vertical Shaft Machining

All soft machining – from cutting to size and centering through to deep drilling and multi-axis turning (up to 4 axes possible) – is performed on VTC 250 DUO machines.
Chang'an Automobile decided to handle the comprehensive turning, drilling and grinding work required for this critical engine part with a multi-stage production line from EMAG that performs all of the machining processes vertically, a process that offers many benefits.
Turning Centers

He Who Brakes, Wins

Automated production at Precima includes batch sizes of 2,000 brake housings per week.
To be able to produce 40,000 brakes a month and maintain consistent quality, Precima invested in four advanced vertical pick-up turning machine tools from EMAG to produce housings for brakes used primarily in wind turbines.
Wire EDM Machines

Wire Changing EDM Proves Big in Micro Tooling Production

Mike (right) and Eric Blackwell of Scenic Tool and Stamping rely on a CUT 2000 wire EDM from GF AgieCharmilles that uses new third-generation twin-head automatic wire changing to easily achieve surface finishes of .2 Ra. (Click on photo to enlarge it)
As consumer products continue to shrink in size, die shops such as Scenic Tool and Stamping face the challenge of developing highly intricate tooling for stamping the tiny components that make up miniature merchandise. As a result, an increasing number of these shops are incorporating high-precision wire EDMs like the Cut 2000 from GF AgieCharmilles that provide automatic wire-changing capability. uses the to easily switch wires of different sizes and materials.
Metal Cutting: Products

Another Look at Aerospace Machining

The tooling area of an EMAG PO 900 BF for the machining of blisks using Precise Electro-Chemical Machining (PECM) technology.
Competitors in this demanding hotbed of manufacturing are being pushed to find new ways of producing more complex parts. Here are some systems that can help them meet their needs.

Highly Effective Machining of Small Aluminum Parts with 3D Contours

The a61nx-5E 5-axis horizontal machining center from Makino achieves highly productive and economical aluminum machining of small components with 3D contours.

How a Flexible Manufacturing System Advances the Science of Machining

Take a look at how this flexible manufacturing system (FMS) from Makino has become a cost-competitive solution for the high-mix, low-volume production requirements at Micro-Mechanics.
Events Calendar
September 21 - 24, 2014
Hilton Chicago -- Chicago, IL
September 23 - 24, 2014
Schaumburg Convention Center -- Schaumburg, IL
September 23 - 24, 2014
The International Centre -- Toronto, Ontario
September 24, 2014
FARO Headquarters -- Lake Mary, FL
September 24 - 27, 2014
Shanghai New International Expo Center -- Shanghai, China